Hydrocarbon hydroprocessing catalyst

ABSTRACT

A HYDROPROCESSING CATALYST OF AN ALUMINA-CONTAINING CARRIER MATERIAL, A NICKEL COMPONENT AND AN IRON COMPONENT. THE CATALYST IS PREPARED VIA COEXTEUSION WHICH INHIBITS THE FORMATION OF NICKEL ALUMINATE TO THE EXTENT THAT LESS THAN ABOUT 0.1% THEREOF APPEARS IN THE FINAL CATALYTIC COMPOSITE.

United States Patent US. Cl. 252-466 J 3 Claims ABSTRACT OF THE DISCLOSURE A hydroprocessing catalyst of an alumina-containing carrier material, a nickel component and an iron compo nent. The catalyst is prepared via coextrusion which inhibits the formation of nickel aluminate to the extent that less than about 0.1% thereof appears in the final catalytic composite.

APPLICABILITY OF INVENTION Hydrocarbon hydroprocessing alludes to the conversion of hydrocarbonaceous material in which a chemical consumption of hydrogen occurs. Principal among hydroprocesses are hydrocracking of heavier hydrocarbons into lower-boilin g products and hydrotreating, or hydrorefining, wherein a hydrocarbonaceous feed stock is cleaned up in order to prepare a charge stock suitable for utilization in a subsequent hydrocarbon conversion process. Although applicable to other hydrogen-consuming processes-Le. the hydrogenation of aromatic hydrocarbons-the present invention is particularly directed toward a catalytic composite which exhibits an unusual degree of stability when utilized in a hydrocracking process.

With respect to a hydrorefining process, the same is widely employed to produce a substantially saturated charge stock, for use, for example, in a catalytic reforming process, which charge stock is substantially free from sulfurous and nitrogenous compounds. Hydrorefining is not, however, limited to improving the physical and chemical characteristics of a naphtha boiling range charge stock, but is equally applicable to higher boiling feed stocks.

The literature is replete with a multitude of processes and catalysts to be employed in the treatment of heavier charge stocks including kerosenes, light gas oils, full boiling range gas oils, heavy gas oils and even black oils. In petroleum refining technology, a black oil is considered to be one containing excessive quantities of sulfurous and nitrogenous compounds, high molecular weight organometallic complexes and a considerable quantity of asphaltic material. Black oils are further characterized as containing non-distillable material having a normal boiling point above a temperature of about 1050 F.

The present invention is especially advantageous when utilized in a process for hydrocracking hydrocarbonaceous material to produce lower-boiling hydrocarbon products. The principal advantage stems from increased catalytic stability, or the capability to perform the intended function in an acceptable manner for an extended period of time. Thus, the present invention can be utilized for the maximum production of LPG (liquefied petroleum gas) in the propane/ butane range from naphtha, or gasoline boiling range fractions. Heavier charge stocks, including kerosenes, light gas oils, heavy gas oils and black oils can be converted into lower-boiling products including gasolines, kerosenes, middle-distillates, etc.

The catalytic composite which constitutes the present invention is considered a dual-function catalyst. That is, it possesses both hydrogenation activity and cracking activity. It is not only important that the dual-function catalyst exhibit the capability to perform its specified functions initially, but also that it has the propensity to perform such functions satisfactorily for prolonged periods of time.

3,825,505 Patented July 23, 1974 Ice The analytical terms employed in the petroleum refining art, to measure the degree to which a particular catalyst performs, are activity, selectivity and stability. For the purposes of discussion herein, these terms are conveniently defined, for a given charge stock as follows: (1) activity is the measure of the ability of the catalyst to convert the hydrocarbon reactants into products, at a specified severity level, wherein severity level connotes the conditions employed; (2) selectivity refers to the quantity of the reactants that are converted into the desired product and/or products; and, '(3) stability refers to the rate of change of activity and selectivity parametersthe smaller rate implying the more stable catalyst.

With respect to hydrocracking, for example, activity, stability and selectivity are similarly defined, and, for the most part, allude to the same considerations. Thus, activity refers to the quantity of charge stock, boiling above a given temperature which is converted to hydrocarbons boiling below the given temperature. Selectivity connotes the quantity of converted charge stock which boils below the desired end point of the product, and above a minimum specified initial boiling point. Stability refers to the rate of change of activity and stability. For example, where a gas oil, boiling above about 650 F., is subjected to hydrocracking, activity connotes the conversion of 650 F.- plus charge stock into 650 F.-minus product. Selectivity might allude to the degree of conversion into gasoline boiling range hydrocarbonsi.e. pentanes and heavier normally liquid hydrocarbons boiling up to about 400 F. Stability might be conveniently expressed in terms of temperature increase required during various increments of catalyst life, in order to maintain the desired activity.

OBJECTS AND EMBODIMENTS The principal object of the present invention is to provide a novel catalytic composite for utilization in the conversion of hydrocarbonaceous material.

Another object is to provide an improved process for hydrocracking a hydrocarbon feed stock, which process is effected through the use of a coextruded catalytic composite of an alumina-containing carrier material, a nickel component and an iron component.

Therefore, in one embodiment, the present invention provides a catalyst comprising coextruded particles of an alumina-containing, porous carrier material, a nickel component and an iron component, and containing less than about 0.1% by weight of nickel aluminate.

In another embodiment, the hydrocracking conditions include a maximum catalyst bed temperature of about 600 F. to about 900 F., a pressure of about 500 to about 5,000 p.s.i.g., a liquid hourly space velocity of about 0.1 to about 10.0 and a hydrogen concentration of about 1,000 to about 50,000 s.c.f./bbl.

Other objects and embodiments of my invention relate to additional details regarding the preferred catalytic ingredients, the concentration of components within the catalytic composite, the method of catalyst preparation, preferred processing techniques and similar particulars which are hereinafter set forth in the following, more detailed summary of my invention.

SUMMARY OF THE INVENTION Catalytic composites which are tailored for the conversion of hydrocarbonaceous material, and particularly in a hydrocracking or hydrorefining process, have traditionally consisted of metallic elements chosen from Groups VI-B and VIII of the Periodic Table. In general, preferred metal components have been nickel and molybdenum, or nickel and tungsten, and these components are generally combined with a porous carrier material comprising both alumina and silica, which is either amorphous, or zeolitic in nature. Ample evidence may be found in the literature to indicate that the nickel component materially contributes to the desired activity of such catalytic composites. A perusal of the published literature relative to this phase of catalysis, confirms the effect of nickel on catalytic activity. Furthermore, the prior art indicates a preference for two particular methods of catalyst preparation. One method, predominantly preferred, involves impregnating a previously calcined, preformed carrier material, generally in the form of spheres or pills, with suitable soluble compounds of the nickel component and the Group VI-B component, where utilized. The impregnating technique is generally followed by drying at a temperature of about 300 F. and calcination at a temperature of about 1100 F. The second preparation scheme involved coprecipitating all the components, including those of the carrier material. For example, an aqueous solution of aluminum chloride, sodium silicate and nickel chloride is formed and coprecipitated by the addition of ammonium hydroxide. While speculatively teaching that the final catalytic composite may take the form of extrudates, the prior art quite clearly indicates an overwhelming preference for spheres and/or pills, which are impregnated with the metallic components, or coprecipitated therewith.

Investigations in the area of nickel-containing catalysts have indicated that an acceptable coextruded catalyst is not readily prepared. The poor results obtained with such catalysts appear to be inherent in the catalyst manufacturing method. Extrudates are generally prepared by a technique which involves coprecipitating the carrier material and the nickel component, followed by filtering and lowtemperature drying, the resulting precipitate being rehydrated to a proper consistency for extrusion. The extrudates are then subjected to drying and high-temperature calcination. During this calcination step, the nickel components reacts with alumina to form nickel aluminate which effectively destroys the desired activity of the nickel component, particularly with respect to hydrocracking and hydrorefining.

A very active and stable hydroprocessing catalyst can be prepared in the form of extrudates by coextruding the preformed alumina-containing carrier material with the nickel component in the presence of an iron component. When the formed extrudates are dried and calcined, the presence of the iron component inhibits the reaction of the nickel component with the alumina to the extent that less than 0.1 by weight of the nickel aluminate deactivating influence is produced.

Other advantages include the attractive economics attendant a more simple and faster catalyst preparation technique. It will be immediately recognized by those possessing expertise in the art of catalyst manufacturing schemes, that coextrusion eliminates several tedious steps involved, for example, in an impregnation technique. Fur- Y thermore, equipment of large capacity is possible, leading to greater catalyst production in a shorter period of time. 'One principal advantage resides in the production of catalyst particles, coextrudates, having pore diameters in the highly desired range of about 100 to about 300 Angstroms. Control of the pore diameter, or size, is readily regulated by the pressure imposed during the initial formation of the extrudates. With respect to spheres and/or pills, control of pore diameter is available only through precise and tedious monitoring of the apparent bulk density.

An essential feature of the present invention is that the porous carrier material be preformed prior to coextrusion with the catalytically active metallic components. It is preferred that the porous carrier material be an adsorptive, high-surface area support. Suitable carrier materials are selected from the group of amorphous refractory inorganic oxides including alumina, titania, zirconia, silica, chromia, magnesia, boria, hafnia, and mixtures of two or more including alumina-zirconia, silica-alumina, aluminasilica-boron phosphate, etc. When of the amorphous refractory inorganic oxide type, a preferred carrier material constitutes a coprecipitated composite of alumina and silica, with silica being present in an amount of from about 10.0% to about 90.0% by weight. In many applications of the present invention, the carrier material will consist of a crystalline aluminosilicate. This may be naturally-occurring, or synthetically-prepared, and includes mordenite, faujasite, Type A or Type U molecular sieves, etc. The porous carrier material may be a mixture of the two wherein a zeolitic material is dispersed within an amorphous matrix. It is understood that the preparation of the catalyst does not involve coprecipitation of the active metallic components with the carrier material. The latter is preformed prior to any contact with the nickel or iron component. Following the formation of the coextruded extrudates, the final composite will generally be dried at a temperature in the range of about 200 F. to about 600 F., for a period of from 2 to about 24 hours or more, and finally calcined at a temperature of about 700 F. to about 1200 F., in an atmosphere of air, for a period of about 0.5 to about 10 hours. When the carrier material comprises a crystalline aluminosilicate, it is particularly preferred that the calcination temperature not exceed about 1000 F.

The initial step in the catalyst preparation method involves commingling the preformed carrier material, for example, a composite of 63.0% by weight of alumina and 37.0% by weight of silica with salts of nickel and iron. Such salts include nickel nitrate hexahydrate, nickel chloride, nickel bromide, iron chloride, iron bromide, iron acetate, iron formate, iron fluoride, iron nitrate, etc. Proportions are utilized which will result in a final catalytic composite comprising from about 1.0% to about 10.0% by weight of said nickel component and from 0.1% to about 5.0% by weight of the iron component, both of which are calculated as the elemental metals. The solid mixture is ground to a talc-like powder, about 20 to mesh, preferably from 30 to 50 mesh, and intimately admixed with a relatively minor quantity of a suitable acid, such as hydrochloric acid, nitric acid, etc. A preferred technique involves mulling the acidic mixture which is subsequently aged for a period of about fifteen minutes to about twenty hours. The Group VI-B metal component, where desired, in a concentration of 4.0% to about 30.0% by weight, is added at this stage of the preparation technique through the use of a suitable compound .such as ammonium molybdate, tungstic acid, r'nolybdic acid, ammonium tungstate, etc. This mixture is again subjected to mulling and a quiescent age for a period of about fifteen minutes to about two hours. The resulting plastic-type mass is extruded under a suitable pressure in the range of about 1,000 to about 10,000 p.s.i.g., to form extrudates of the desired sizee.g. A -inch by A -inch. After drying and calcining in the manner hereinbefore set forth, analysis indicates that the extrudates contain less than 0.1% by weight of nickel aluminate.

Although not essential to successful hydroprocessing, it is often advisable to incorporate a halogen component into the catalytic composite, particularly where the same is to be utilized in a hydrocracking process. Although the precise form of the chemistry of association of the halogen component with the carrier material and the metallic components is not accurately known, it is customary in the art to refer to the halogen component as being combined with one of the other ingredients in the catalyst. The halogen may be either fluorine, chlorine, iodine, bromine, or mixtures thereof, with fluorine and chlorine being particularly preferred. The quantity of halogen is such that the final catalytic composite contains from 0.1% to about 3.5% by weight, and preferably from about 0.5% to about 1.5% by weight, calculated on the basis of the elemental halogen.

Prior to its use in the conversion of hydrocarbons, the catalytic composite may be subjected to a substantially water-free reduction technique. Substantially pure and dry hydrogen (less than about 30.0 volume p.p.m. of water) is employed as the reducing agent. The calcined catalytic composite is contacted at a temperature of about 800 F. to about 1200 F., for a period of about 0.5 to about hours, and effective to substantially reduce the metallic components.

Additional improvements are generally obtained when the reduced composite is subjected to a presulfiding operation for the purpose of incorporating therein from about 0.05% to about 0.5% by weight of sulfur, on an elemental basis. This presulfiding treatment is effected in the presence of hydrogen and a suitable sulfur-containing compound such as hydrogen sulfide, lower molecular weight mercaptans, various organic sulfides, carbon disulfide, etc. The preferred technique involves treating the reduced catalyst with a sulfiding gas, such as a mixture of hydrogen and hydrogen sulfide having about 10 moles of hydrogen per mole of hydrogen sulfide, at conditions selected to effect the desired incorporation of sulfur. It is generally considered good practice to perform the presulfiding technique under substantially water-free conditions.

In accordance with my invention, the hydrocarbon charge stock and hydrogen are contacted with a catalyst of the type described above in a hydrocarbon conversion zone. Thecontacting may be accomplished by using the catalyst in a fixed-bed system, a moving-bed system, a fluidized-bed system, or in a batch-type operation. In view of the risk of attrition loss of the catalyst, and further in view of the technical advantages attendant thereto, it is preferred to use a fixed-bed system. In this type of system, a hydrogen-rich vaporous phase and the charge stock are preheated by any suitable heating means to the desired initial reaction temperature, the mixture being passed into the conversion zone containing the fixed-bed of the catalyst composite. It is understood, of course, that the hydrocarbon conversion zone may consist of one or more separate reactors having suitable means therebetween to insure that the desired conversion temperature is maintained at the inlet to one or more catalyst beds. The reactants may be contacted with the catalyst in either upward, downward or radial flow fashion, with a downward/ radial flow being preferred.

Hydroprocessing reactions are generally exothermic in nature, and an increasing temperature gradient will be experienced as the hydrogen and charge stock traverse the catalyst bed. It is desirable to maintain the maximum catalyst bed temperature below about 900 R, which temperature is virtually identical to that which may be conveniently measured at the outlet of the reaction zone. In order to insure that the catalyst bed temperature does not exceed the maximum allowed, conventional quench streams, either normally liquid or normally gaseous, introduced at one or more intermediate loci of the catalyst beds, may be utilized. When hydrocracking hydrocarbonaceous charge stocks, a portion of the normally liquid product efiluent boiling above the end boiling point of the desired product will generally be recycled to combine with the charge stock. In this type of process, the combined liquid feed ratio (defined as volumes of total liquid charge to the reaction zone per volume of fresh liquid to the reaction zone) will be within the range of about 1.1 to about 6.0.

ILLUSTRATIVE EMBODIMENT Specific operating conditions, processing techniques, a particular catalytic compositeand other individual process details will be given in the following description of a process to which my invention is applicable. It is not intended that the present invention be limited to the specifics, nor is it intended that a given process be limited to these particular operating conditions, the catalytic composite, processing techniques, charge stock, etc. Therefore, it is understood that the present invention is merely illustrated by the specifics hereinafter set forth. The embodiment will be described in conjunction with a hydrocracking process intended to produce maximum quantities of a heptane- 400 F. gasoline fraction from a full boiling range gas oil.

In general, hydrocracking conditions will include a maximum catalyst bed temperature of about 600 F. to about 900 F., a pressure of about 500 to about 5,000 p.s.i.g., a liquid hourly space velocity of about 0.1 to about 10.0 and a hydrogen concentration in the range of about 1,000 to about 50,000 s.c.f./bbl. Obviously, the precise operating conditions in a given circumstance will depend primarily on the physical and/or chemical characteristics of the charge stock, as well as the desired end result.

The charge stock is processed in two stages, the first of which effects the hydrorefining of the feed stock with some conversion to lower-boiling products, while the second effects the conversion of material boiling above 400 F. into normally liquid, naphtha boiling range hydrocarbons. The hydrorefining catalyst is prepared by commingling finely-divided nickel nitrate hexahydrate and iron chloride with a preformed carrier material of 63.0% by weight of alumina and 37.0% by weight of silica. The solid mixture is ground to a powder having a size of about 40 mesh. This is intimately admixed with concentrated nitric acid and water by mulling, and subsequently aged for a period of about hour. Ammonium molybdate is added to the aged mixture, the same is mulled, and aged again for a period of about /2 hour. The resulting plastic-type mass is extruded at a pressure of about 4,000 p.s.i.g., to form 5 -inch by A -inch (approximate measurements) extrudates. These are dried at a temperature of about 225 F. for three hours and calcined, in an atmosphere of air, at a temperature of about 1100" F. for a period of about one hour. Analyses indicate that the extrudates have an apparent bulk density of about 0.75 and contain 3.4% by weight of nickel, 1.7% by weight of iron and 6.8% by weight of molybdenum calculated as the elemental metals; the concentration of nickel aluminate is less than about 0.1% by weight. The hydrocracking catalyst is prepared in much the same manner utilizing a carrier material of 75.0% by weight of silica and 25.0% by weight of alumina. The concentration of the nickel and iron components are increased, while the molybdenum component is eliminated. Sufficient nickel nitrate hexahydrate and iron chloride are utilized as above to result in a final cata ytic composite containing 6.0% by weight of nickel and 3.0% by weight of iron; the finished catalyst has an apparent bulk density of about 0.82.

In a two-stage system, functioning in series-flow, the focal point for pressure control is the cold separator into which the second zone efiiuent is introduced. In the present illustration, the pressure on the hydrorefining reaction zone is maintained at a level such that the cold separator pressure is 2,000 p.s.ig. The charge stock, having the properties set forth in the following Table I, in an amount of about 3,000 bbl./day, is admixed with about 10,000 s.c.f./bbl. of hydrogen and introduced into the hydrorefining reaction zone at a temperature such that the maximum catalyst bed temperature is about 850 F. The liquid hourly space velocity through the catalyst bed is about 0.87.

Yields and product distribution with respect to the efiluent from the hydrorefining reaction zone are presented in the following Table II.

TABLE I: Gas Oil Charge Stock Properties The yields indicated in the foregoing Table IIare inclusive of a hydrogen consumption of 1.081 s.c.f./bbl. (1.78% by weight of fresh feed charge stock). The total product efiluent from the hydrorefining reaction zone is admixed with about 1,640 bbL/day of a recycle stream comprising hydrocarbonaceous material boiling above a temperature of about 400 F. The liquid hourly space velocity, based upon fresh feed only, is about 0.55 and the combined liquid feed ratio is 1.60. The maximum catalyst bed temperature is 800 F., and the increasing temperature gradient is maintained at about 80 F. through the utilization of 3,900 s.c.f./bbl. of hydrogen as a quench stream. An additional 1,014 s.c.f./bbl. (1.67% by weight) of hydrogen are consumed in the hydrocracking reaction zone. Following separation of the product efliuent, the unconverted material boiling above a temperature of about 400 F. is recycled to combine with the material being charged to the hydrocracking reaction zone. Overall yields and product distribution are presented in the following Table III.

TABLE TIL-OVERALL PRODUCT DISTRIBUTION AND YIELDS Weight Volume 8 With respect to the desired heptane-400 F. naphtha boiling range fraction, the same has a gravity of about 53.3 API and contains 40.4% by volume parafiins, 46.5% naphthenes and 13.1% aromatics. It will be recognized that this product stream constitutes an excellent charge stock for a subsequent catalytic reforming unit. Thecombined pentane/hexane stream, having a gravity of about 82.5 API, has a clear research octane rating of about 83.5 and a leaded research octane rating of about 97.9; and can, therefore, be immediately utilized as a blending component for the refinery gasoline pool.

The foregoing illustrates the method of effecting the present invention as well as the benefits to be afforded through the utilization thereof.

I claim as my invention:

1. A catalyst comprising coextruded particles of an alumina-containing, porous carrier material, a nickel component and an iron component, and containing less than about 0.1% by weight of nickel aluminate.

2. The catalyst of Claim 1 further characterized in that said carrier material is an amorphous refractory inorganic oxide.

3. The catalyst of Claim 1 further characterized in that the nickel component is in an amount of from about 1.0% to about 10.0% by weight and said iron component is in an amount of from about 0.1% to about 5.0% by weight, calculated as the elemental metals.

References Cited UNITED STATES PATENTS 3,580,970 5/1971 Swift 252-466 J 3,471,397 10/1969 Fortman 208-l1l 3,617,527 11/1971 Hilfman 252466 JX CARL F. DEES, Primary Examiner 

